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Transporter T4 workshop manual
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100% found this document useful (11 votes)
22K views211 pagesVolkswagen T4 WorkShop 1990-1995
Transporter T4 workshop manual
Uploaded by
FernandoCopyright
© © All Rights Reserved
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Available Formats
Download as PDF or read online on Scribd
/ 211
A
VOLKSWAGEN
TRANSPORTER T4
WORKSHOP MANUAL
(Powered by 2.0 & 2.5 petrol and 1.9 & 2.4 diesel engines)
Petrol & Diesel models - 1990 to 1995
OWNERS EDITION VOLKSWAGEN
TRANSPORTER T4
WORKSHOP MANUAL“
(Powered by 2.0 & 2.5 petrol and 1.9 & 2.4 diesel engines)
Petrol & Diesel models - 1990 to 1995
OWNERS' EDITION
COVERING
SHORT & LONG WHEELBASE © VAN + CARAVELLE ¢ BUS
2.0 & 2.5L PETROL AND 1.9 & 2.4L DIESEL ENGINES
MANUAL TRANSMISSION & DRIVE SHAFTS * CLUTCH
FUEL, IGNITION, LUBRICATION & COOLING SYSTEMS 7
SUSPENSION + STEERING ¢ BRAKING + ELECTRICS f
BODYWORK ° PLUS WIRING DIAGRAMS
ab CONTENTS
General Information, Dimensions, Weights, Capacities, 5
Servicing Notes.
Chapter One Four-Cylinder Petrol Engines 10
Chapter One A Five-Cylinder Petrol Engines 38
Chapter Two Ignition System 56
Chapter Three Lubrication System - Petrol Engines 62
Chapter Four Cooling System - Petrol Engines 68
Chapter Five Fuel Injection System - Four Cylinder 74
Chapter Six Fuel Injection System - Five-Cylinder 83
Chapter Seven Exhaust System 84
Chapter Eight Clutch 88
Chapter Nine Manual Transmission 93
Chapter Ten Drive Shafts 98
Chapter Eleven Power-Assisted Steering 102
Chapter Twelve Front Suspension 112
Chapter Thirteen Rear Axle and Rear Suspension 124
Chapter Fourteen Brake System 131
Chapter Fifteen Electrical Equipment 145
Chapter Sixteen Diesel Engines 152
Chapter Seventeen Engine Lubrication - Diesel Engines 174
Chapter Eighteen Engine Cooling System 177
- Diesel Engines
Chapter Nineteen Diesel Injection System 178
Chapter Twenty Diesel Engines - Tightening Torques 188
Chapter Twentyone Bodywork 191
Fault Finding Section 198
Wiring Diagram Index 206 FOREWARD
This Owners’ Edition - Workshop Manual covers the VW Transporter Type 4 (T4) winich
was introduced in December 1990 fitted with 2.0 and 2.5 litre petrol engines and 1.9,
and 2.4 litre diesel engines. It has been specially written for the practical owner who
wants to maintain a vehicle in first-class condition and carry out the bulk of his or her
‘own servicing and repairs. Comprehensive step-by-step instructions are provided for
service and overhaul operations to guide the reader through what might otherwise be
unfamiliar and complicated tasks. Numerous drawings are included to amplify the text.
With the aid of this manual, many aspects of service, overhaul and repair are within the
scope of an owner with a reasonable degree of mechanical aptitude. Some operations
however demand more skil. Other jobs require the use of special tools and in some
cases testing facilities and techniques that are not generally available. Only you can
judge whether a job is within your capabilities. We do however try to assist the reader to
come to an informed decision. Whilst every effort has been made to ensure that the
information provided is correct, it is obviously not possible to guarantee complete free-
dom from errors or omissions.
Information to be found in the driver's handbook is not necessarily duplicated here and
itis not possible within this volume to cover every aspect to be found in the manufactur-
er's own workshop manual which is of much greater size and complexity. However, it
should be consulted if more detailed information is needed.
Always remember that you are responsible for your own safety and that of others when
working on a vehicle. Take particular care with safety-related systems like the brakes
and steering, and seek professional advice if in any doubt. Never work under a vehicle
Unless it is properly supported (a single jack is not enough). Take care with power tools,
also regard as potentially harmful fuel, lubricants, solvents and sealers which should
always be and kept in labelled, sealed containers.
With care and common sense, the practical owner can make an excellent job of mainte-
nance and overhaul. The benefits include money saved and the satisfaction of work
well done. You will be adding to your knowledge, too: knowing more about the vehicle
you own will help you to make logical decisions about what needs to be done, even if it
does in some instances have to go into a professional repair shop.
The Volkswagen Transporter T4 is a vehicle that will respond to careful regular servic~
ingand is built to a standard that will ensure a long life if this is remembered. 0. INTRODUCTION
8.9. General Information
This Manual covers the models in the Volkswa-
gen Transporter range from 1990, generally
selerred to as Type T4 vehicles, with a choice of
mo water-cooled fuel injection engines or two
Sesel engines. The information in this manual is
sesed on the original conception of the vehicle.
Tee following engines are covered in this ma-
nal:
® The 2.0 litre fuel injection engine has the type
designation “AAC”. The engine has a perfor-
mance of 62 kW (DIN) at 5200 rpm. A
“Digifant” system, combining the fuel injec-
‘ton and ignition system, is fitted to the
engine,
© The 1.9 litre diesel engine is a four-cylinder
‘engine and has the type designation "1X"
‘The engine has a performance of 45 kW at
3700 rpm.
© The 2.4 litre diesel engine is a five-cylinder
‘engine and has the type designation “AB”.
The engine has a performance of 57 kW at
3700 rpm.
© A further engine in the T4 range is a five-
cylinder engine with fuel injection. This engine
is covered in its own chapter, but is similar in
construction to the 2.4 litre diesel engine, i.
the crankcase, crankshaft and piston assem-
blies are of a similar design.
The front suspension consists of an upper and
ower wishbones, torsion bars and a stabiliser
sar (anti-roll bar), together with double-acting,
sydraulic shock absorbers. The individual parts
the front suspension can be removed from the
sehicle without dismantting the complete assem-
ly. All parts of the front suspension are mount-
xd to a strong crossmember, which can be
emoved as a complete unit in order to remove
the individual units, if major repairs are ne-
cessary.
‘The rear suspension consists of suspension
arms with coil springs and hydraulic shock ab-
sorbers and a stabiliser (anti-oll) bar. The sus-
pension arms are rubber-mounted on the
chassis. The wheel hub carrier is bolted to the
outside of the suspension arm. The connection
to the rear drive shafts takes place at the inside
of each rear wheel hub cartier.
A rack and pinion steering, fitted with power-
assistance, is used.
Disc brakes at the front wheels and drum brakes
at the rear wheels with a brake servo unit as
standard fitment, make up the brake system.
‘A four-speed, a five-speed or an automatic trans-
mission can be fitted to the vehicles covered in
this manual.
With regards to the range of models covered in
the manual it must be pointed out that not all of
these will be available in any particular country
and that the manufacturer reserves the right to
make modifications to standard equipment, op-
tional extras and trim as may be necessary for
any territory.
Since the variations between certain models are
only in fittings and trim it will be unnecessary in
‘some paris of this manual to refer to individual
model designations.
0.1.
The type identification plate can be found near
the front door pillar, close to the door striker
plate, at the position shown in Fig. 0.1. The
chassis number is stamped into the the right-
hand side, below the windscreen, and is visible
,
Note: Always
Identify your en-
gine by means of
the code letters
before ordering
spare or replace-
ment parts or car-
tying out any
repairs. The chas-
sis number Is im-
portant for other
parts of the ve-
hicle. Fig.03.
‘Theloctionoftheengine
rumberonthe ptr!
engin.
Fig.04.
‘Thepositonotineengine
rumberonthe dase
engine
.
6 .
Introduction
from the outside of the vehicle (arrow, Fig. 0.2). The
chassis number can have the following appear-
anc
Wvw222ZZ:370ZMH00001
which relates to the following data:
© The first three letters with the "2" refer to the
code letters ofthe manufacturer.
© Thenextthree letters (222) are filerletters.
© The number “970” refers to the model
designation.
© Thesingle"'Z"isatfilerietter.
© Theletter‘'M” refers to the model year, in this
case 1981, Following model years are identified by
subsequentletters.
@ The "H” refers to the manufacturing plant in
Germany.
© Thelastnumbersare the actual serialnumber
ofthevehicle.
‘The engine numbers stamped into the front of the
jer block. In the case of the petrol engine the
numberis located below two of the spark plugs and
ives the code letters of the engine and the actual
‘engine serial number. The engine number is also
‘shown on the timing belt cover andon sticker, atta
ched to the engine. Fig. 03 shows where thenum-
bercan be foundoon this engine. The enginecodeis
also givenin the type identification plate on the door
pillar.
‘The engine number of a diesel engine is stamped
into the cylinder block between the injection pump
and the vacuum pump, atthe position shown in Fig.
0.4, Again the engine code and engine serial num-
berare quoted. Asticker with the engine code and
the engine numberis attached to the upper timing
beltcover.
Thesenumbers are the essential information nee-
ded whenever spares or replacement parts arere-
Quired. The vehicle manufacturer operates apolicy
ofconstantimprovement and updating and itis only
by quoting the vehicle and engine numbers that
your dealer can provide you with the correct spares
and replacements,
0.2. Dimensions (typical)
Wheelbase: +++ -2920mm(t160in)
(0r3320 mm (131.9in.)
Fronttrack:
14 rims: 1575mm (628in.)
15" rims: 1589 mm 63.13in,) a
Rear Track:
14" rims: 1540 mm (61.2 in.)
15" rims: 1.1554 mm (62.75 in.)
Min, ground clearanc
Standard version:
GTI versi
+180 mm (7.15 in)
160 mm (6.36 in.)
0.3. Capacities
Engine Oil — Petrol Engine:
Four-cylinder/Five-cylinder — Without filter
= Witt fit
Four-cylinder diesel engine — Without filter
— With filter:
Five-cylinder diesel engine — Without filter
— With filter:
Manual transmission:
‘Automatic transmission:
Initial filing:
Fluid change: .
Differential and Final Drive:
‘Automatic:
Cooling system:
0.4. General Servicing Notes
The servicing and overhaul instructions in this
Workshop Manual are laid out in an easy-to-
follow step-by-step fashion and no dificuity
should be encountered if the text and diagrams
are followed carefully and methodically. The
“Technical Data” sections form an important
part of the repair procedures and should always
be referred to during work on the vehicle.
In order that we can include as much data as
possible, you will find that we do not generally
repeat in the text the values already given under
the technical data headings. Again, to make the
best use of the space available, we do not repeat
‘at each operation the more obvious steps neces-
‘sary — we fee! it to be far more helpful to con-
centrate on the difficult or awkward procedures
in greater detail. However, we summarise below
a few of the more important procedures and
draw your attention to various points of general
interest that apply to all operations.
‘Always use the torque settings given in the vari-
‘ous main sections of the manual. These are
grouped together in separate sub-sections for
Convenient reference.
Bolts and nuts should be assembled in a clean
0 Introduction
Turning circle:
Short wheelbase: .....11.7 metres (38.6 ft.)
Long wheelbase: .....12.9 metres (42.6 ft.)
8.5 litres (6.1 Imp. pt.V5.0 litres (8.77 Imp. pts)
40 litres (7.0 Imp. pts.V'5.5 litres (9.7 Imp. pts.)
css 48 litres (8.00 Imp. pts.)
11.15. litres (8.75 Imp. pts.)
5.0 litres (8.8 Imp. pts.)
5.5 litres (9.6 Imp. pts.)
+ 2.0 litres (3.5 Imp. pts.)
6.0 litres (10.4 Imp. pts.)
3.0 litres (5.25 Imp. pts.)
at 1.28 litres (2.2 Imp. pts.)
9.0 litres (2 Imp. gall), all engines
and very lightly oiled condition and faces and
threads should always be inspected to make
sure that they are free from damage, burrs or
scoring. DO NOT degrease bolts or nuts.
All joint washers, gaskets, tabs and lock wash-
ers, split pins and "0" rings must be replaced
‘on assembly. Oil seals will, in the majority of
cases, also need to be replaced, ifthe shaft and
seal have been separated. Always lubricate the
lip of the seal before assembly and take care
that the seal lip is facing the correct direction.
References to the left-hand and right-hand sides
are always to be taken as if the observer is at
the rear of the vehicle, facing forwards, unless
otherwise stated.
‘Always make sure that the vehicle is adequately
‘supported, and on firm ground, before com-
rmencing any work on the underside of the car. A
small jack or a make shift prop can be highly
dangerous and proper axle stands are an essen-
tial requirement for your own safety.
Dirt, grease and mineral cl will rapidly destroy
the seals of the hydraulic system and even the Fig. 05.
Jacking upthe rontendot
‘hovonicle Theifustration
lackisapplidatthe same
postion.
”
0 Introduction
‘smallest amounts must be prevented from entering
the system or coming into contact with the
‘components. Use clean brake fiuid or one of the
propritory cleaners to wash the brake hydraulic
system parts. An acceptable alternative cleaner is
‘methylated spirit, butifthisis used, itshouldnotbe
allowed to remain in contact withthe rubber parts
forlonger than necessary Itisalso important that al
traces of the fluid should be removed from the
system beforefinal assembly.
Always use genuine manufacturer's spares and
replacements for the best results.
Since the manufacturer uses metric units when
building the cars itis recommended that these af
Used for all precise units. Inch conversions are
given in most cases but these are not necessarily
precise conversions, being rounded off for the
tunimportantvalues.
Removal and installation instructions, in this
Workshop Manual, cover the steps to remove or
replace the unit or part in question. Other
instructions, usually headed " Servicing’, will cover:
the dismantling and repair of the unit once it has
been stripped from the vehicle. Itis pointed out that
the majorinstructions cover a complete overhaul of
all parts but, obviously, this will not always be
necessary and should not be carried out
needlessly.
There area numberof variationsin unitpartson the
range of vehicles coveredin this Workshop Manual.
We strongly recommend that you take care to
identity the precise model, and the year of
manufacture, before obtaining any spares or
replacement parts.
Std.: _Toindicate sizes and limits of components
‘as supplied by the manufacturer. Also to
indicate the production tolerances of new
unusedparts.
Parts supplied as Oversize or Undersize,
or recommended limits for such
US paris, tosnable them tobe used with worn
‘or re-machined mating parts. O/S
cates a part that is larger than Sid. size.
UIS may indicate a bore of a bushing or
female partthatis smaller than Std.
Where given against a clearance or.
dimension indicates the maximum
allowable. Ifin excessof the value givenit
is recommended that the appropriate part
isfitted.
TIA: Indicates the Total Indicator Reading as
‘shown by adial indicator (dial gauge).
HT: High Tension (ignition) wiring or terminals.
TDC: Top Dead Centre (No. 1 piston on firing
stroke),
MP: — Multi-Purposegrease.
05. Jackingupof the Vehicle
For small jobs, jack up the vehicle as described in
the Owner's Manual, with the jack supplied in the
vehicle. Ifa mobile jackis used, make sureitcan be
inserted between the lowest point of the vehicle and
the ground. Itnecessary, use the vehicle jack lift
the the vehicle slightly, until the mobile jack can be
inserted. Due to the construction of the vehicle, a
‘mobile jack andlor chassis stands should only be
placed under the vehicle as follows, noting that a
piece of rubber or wood should always be inserted
between the jack head and the jacking point to
protectthe partin question.
Never apply a mobile jack or @ hydraulic jack
underneath the enginecil sump, the transmission,
the rear axle, the frontaxle or underneath the front
‘crossmember, as these parts or surrounding parts.
caneither be damaged or distorted.
‘The recommendation isto first jack up one side of
the vehicle, placing achassis stand undemeath the
body and then jacking up theotherside.
To jack-up the front of the vehicle, place the jack
underneath the crossmember at the position
‘shown in Fig. 05. Chock the front and rear wheels
‘on the other side of the vehicle with a brick, to
prevent the vehicle from rolling off the jack. Also
‘apply the handbrake.
‘Tojack up the rear end of the vehicle, place the jack
head underneath the mounting bracket of the rear
Suspension arm, as shown in Fig. 06. Engage a (gear and chock the front and rear wheels on the
other side. Also apply the handbrake.
Strong chassis stands must be placed under-
neath the sides of the body. The bolt, used for
the height adjustment of the stands (Fig. 0.7)
‘must be strong enough to carry the weight of the
vehicle — remember this — make-shift bolts of
‘small diameter will not do.
tis always dificult to raise a vehicle first on one
side and then on the other. Take care that the
vehicle cannot tip-oxer when the first side is lit-
‘ed. Ask a helper to support the vehicle from the
other side.
oO
Introduction
Fig.0.8,
sacking up the rear end of
ite vehicle. The tration
shows a garage-ype jack,
Duta mobil or hydrate
Jacks apple at the same
Postion.
Fig. 0.7.
“Tee-ogged” axle or
‘enasis stands area
Smut” when sspperting
te vahicle uring oper
tione undemeath 10
1 FOUR-CYLINDER PETROL ENGINE
Index
Main Features .
Removal and
Engine with automatic transmission .
Engine Dismantling. ..
Engine — Assembly ..
Servicing and Overhaul
Cylinder Head and Valves...
Introduction ..
Cylinder Head — Servicing ..
Cylinder Head — Assembly.
Cylinder Head — Fitting .
Hydraulic Tappets ............
Replacing the Camshaft Oil Seal .
Pistons and Connecting Rods:
Technical Data
Servicing . .
1.0. Main Features
Type:
Valve gear:
Engine Details:
Bore and stroke:
Compression ratio: 2.0... ee veeee eee
Valve Timing:
Inlet valve opens:
Inlet valve closes:
Exhaust valve opens:
Exhaust valve closes:
Fuel supply: .
Cylinder Block and Intermediate Shaft
Crankshaft and Flywheel
Technical Data
Removal and Installation .
Crankshaft Oil Seals...
Crankshaft Bearings ..
Flywheel
Drive Plate (Automatic) ......
Timing Drive and Camshaft
Introduction ce
Removal and Install
Timing Belt .
Checking and Setting the
Timing Drive
Intermediate Shaft.
Tightening Torque Values .
L
« 4-eylinder, in-line, water cooled engine. Distribu-
tor drive from auxiliary shaft. Engine fitted trans-
versely to the front of the vehicle.
-Overhead camshaft, timing belt drive to cam-
shatt and auxiliary shaft. Camshaft operating
directly onto inverted buckettype tappets
(rydrautic type).
serra AAG,
. .62 KW (85 BHP) at 5200 rpm
12.7 kgm (91 ftlb.) at 2600 rpm
825 x $2.8 mn (.2777 x8009 mn)
. 8:1
3° before top dead centre
“19° atter bottom dead centre
27° before bottom dead centre
, -5® after top dead centre
-"Digitant’ fuel injection system 1 Four-cylinder Petrol Engine
Firing order: . seve Ah?
Idle speed: + +880 £ 50 rpm
CO Content:
With Lambda probe (oxygen sensor) 0.7 40.2%
Without Lambda probe (oxygen sensor): deteeeeeeeeess 1.0 £ 0.5 9%
Ignition timing point: a ‘See Section “Ignition System”
Oil Pressure:
Mino... 0 kg/sq.cm. (14.2 psi.)
Max. 7.0 kg/sq.cm. (99.6 psi.)
4.1, Engine — Removal and Installation
The engine is removed together with the trans-
mission from below the vehicle. A strong mobile
jack must be available. VW workshops use a spe-
ial device to guide the engine. As this will ob-
viously not be available to the average D.LY. man,
‘we recommend that a helper holds the engine on
the jack whilst itis lowered.
4
Before the engine is removed, it is necessary to
tit the radiator and the bonnet lock carrier towards
the front. This operation will also be necessary
for various maintenance and service operations
ind the following description will be referred to
at various stages when required.
© From underneath the vehicle unscrew the
noise dampening panels. Todo this, unscrew the
screws and nuts shown in Fig. 1.1, unlock the
locking lever, lower the panel assembly and take
it out of its mountings. Tighten the screws and
nuts to 0.9 kgm (7 ft.lb.) during installation.
© To tit the radiator towards the front, in the
direction shown by the arrow in Fig. 1.2, remove
the two screws (1) on the L.H. and R.H. side and
then pivot the radiator and the lock plate towards
the front. Lock the lock carrier plate in position.
The removal of the engine can now proceed as
follows:
© Disconnect the battery terminals. The bat-
tery can now be removed from the vehicle since
this will avoid any possibilty of damage or inad-
vertent short-circuiting.
© Place the heater operating lever into the
“Warm” position and remove the cap from the
‘expansion tank. The engine must be cold. Ob-
© Drain the cooling system. To do this, refer to
Fig. 1.3 and slacken the hose clips securing the
Fig. 1.1.
‘The arrows show whore
the rose dampering panel
18 socured underoath the
wohl,
Fig. 1.2.
‘Atorromoval fhe
‘screws (1) on each side of
the vehicle, the com.
plete front ond ofthe voi
{ein the decton of the
‘row.
Fig. 13.
Draining the cooling sy
tm. The numbers ae.
tolered ein the
ff ‘desatinepostions
Shombyine arrows.
a
Fi.t5.
UUnserowtheplugatthe
postion shown fomthe
anamasion andeacure
thaciuchreleaseleverby
Insoring an M822 mm
bot.
12
1 Four-cylinder Petrol Engine
‘wo hoses (2) or unscrew the water pump flange (3).
Itis also possible to remove the drain plug (1) to
drain the cooling system, depending where th
‘workis carried out. As antrfreezeis containedin the
‘cooling system, check the condition of the solution
before deciding whether todrainitorto collectitina
suitable container.
© Siacken the hose clamps on the upper radiator
‘hose and withdraw the hose from the cylinder head.
‘Also disconnect the hose between radiator and
water pump and radiator and expansion tankon the
‘engine or the expansion tank. Hoses are either
secured by means of spring clampsor screw-type
clamps. Spring clamps can be replaced with screw-
type clamps during instalation.
© Knockthe pins outof the spreader clipson the
LH. and R.H. sides of the radiator and remove the
spreader clips from the radiator mounting, Fig. 14
shows where the pins are located. Disconnect the
electrical lead from the temperature switch on the
radiator and the connector for the cooling fan motor.
‘Completely remove the radiator, Remove the hoses
from their connections to create enough room for
the removalof the radiator assembly.
© Disconnect the cable connector plug from the
rear of the alternator and from the side of the
ignition distributor.
© Disconnect the fuel inlet and return pipes from
theirconnections.
© Unhook the throttie operating cable from the
throttle vaive operating segment and detachit from
the bracket. Do not remove the clip securing the
‘cable to the bracket, but unscrew the bracket.
© Disconnect he electrical leads fromthe 1 bar
cll pressure switch and push the lead to one side.
‘Aiso disconnect the leads of allremaining switches,
connections, etc. and all vacuum hoses, after
marking thei terminals andlor connections. These
include the HT. cable in the centre of the distributor,
the temperature sender unit for the water
temperature gauge, the 03 bar oilpressure switch,
andothers.
© If any of the radiator hoses have been left on
the engine connections, remove them now.
© Remove the rubber plug from the hole in the
transmission, shown by the arrow in Fig. 15, and
‘secure the clutch release lever with a pin. The
ilustration shows the special pin used by VW
‘workshops (top right), but an M8 x 22 mm bolt will
do.
@ Remove the coolant pipe between the thermo-
stathousing and the heat exchanger for theheater.
@ Place mobile jack underneath the centre ofthe
engine. Ablock of wood mustbe placed between oil
sump and jack head. Operate the jack until the
engineis slightly under tension.
@ Remove all bolts between engine and
transmission from below the vehicle.
© Removethe rearengine mounting,
© Release the steering pump belt tension and
tnscrew the pump fromthe engine. Place the pump
toone side whereitis outof the way.
© Remove the driveshafts (Chapter 10) and front
‘exhaust pipe.
© Check that engine and transmission are
securely supported on the jack and remove the
‘centre bolt securing the engine mounting on the
R.H. side. Completely unscrew the engine
mounting bracket.
transmission atthe top.
© Withdraw the engi
from the transmission, taking care all the time that the engine cannot
drop off the jack. A second person must operate
the jack slowly. Make sure that none of the con-
nections have been left in position and take care
that no damage is done when the engine is lowe-
ted from the engine compartment. Also make su-
re that the engine cannot rest on the clutch shaft.
Install the engine and transmission in the reser-
ve sequence to removal, noting the following
points below:
© Check the clutch release bearing before in-
stallation of the engine. Slightly coat the contact
face of the release bearing and the clutch shaft
with grease. The guide sleeve for the release be-
aring must not be lubricated.
© Check that the two dowel pins, shown in Fig.
1.6, are located in the cylinder block. Sometimes
they will remain in the transmission, but must be
transfered before the engine is fitted. In this ca-
se, ft new dowel pins, as the original ones may
be damaged when removed from the trans-
mission,
© Coat the intermediate plate on the engine si-
de with grease and place it over the two dowel
pins and against the engine.
© Lift the engine into position in the engine
‘compartment. Again a helper must operate the
Jack as the engine is guided in, When level with
the clutch shaft, push the engine against the
transmission and engage the clutch shaft with the
clutch driven plate. If engagement does not take
place immediately, move the crankshaft to and
fro by pulling on the alternator drive belt. Push
the engine fully against the transmission before
fitting the upper bolts. The gap must be nearly clo-
‘sed before the bolts and inserted and tightened.
© Refit all engine mountings and tighten the
‘bolts to the following torques:
Engine mounting bracket to engine
mounting: 26.5 kgm (47 fb.)
Engine support, right, on cylinder
block: 5.0 kgm (36 ftlb,) + 90°
Engine to Transmissio
MB threads: 2.0 kgm (15 ft.lb.)
M10 thread: 6.0 kgm (43 ft.lb.)
M2 threac 8.0 kgm (58 fb.)
Engine support, rear, on cylinder
block: 45 kgm (32.5 flo.)
Engine suppor, rear, on
transmission: «.2.0kgm (15 ftlb.)
‘Steering pumpicylinder block:2.5 kgm (18 ftlb.)
1 Four-cylinder Petrol Engine
© Re-connect the exhaust pipe to the manifold
‘as described in the relevant section.
© Fill the cooling system as described in Sec-
tion 4. “Cooling”.
© Fill the engine with engine oil. Also check
the transmission oil level and correct if ne-
ceossary.
© Adjust the throttle cable as described in the
fuel section,
© I necessary adjust the ignition and idling
speed after the engine has been restarted.
© Check the headlamp adjustment or have it
professionally checked.
WITH AUTOMATIC
TRANSMISSION
14
The removal and installation of the engine is car-
ried out in a similar manner as described in Sec-
tion 1.1.0, but the following differences should
be noted:
© Unscrew the complete bracket for the throt-
tle cable either from the cylinder head. Do not
disconnect the throttle cable from the bracket.
© Place the transmission selector lever into
position “P” and slacken the clamp nut in order
to release the gearchange cable, Release the
throttle cable by pressing the ball joint connec
tion off the pin, carefully using a screwdriver.
© Release the throttle pedal cable from the
lever connection and unscrew the bracket.
© Unbolt the torque converter from the drive
plate. The converter is secured by three bolts,
‘which will be visible through the opening for the
Fig. 18.
‘The arows show where
tho two dowel pina must
be ft tothe cyinder
lock.
13 © rig.
‘Thodiveplatototorue
conver bowl appear
Inthe anermoteropenng
wwhonthecnginelsottod.
Fig 18.
Ves canbe piereod
{trough un upsicedown
‘cardboardboxwahihe
‘alvenumberwriten
‘againseachvaive.
Fig.t9.
‘Tatighening sequence
lorthacyinderheadbots
Slackon ne bots inverse
oer
4
1 Four-cylinder Petrol Engine
starter motor. Rotate the engine until the bolts
appearone after the other, as shownin Fig. 17 and
unscrew them.
© Refer to Section 1.1.0 when installing the
engine and transmission. The installation is a
reversal of the removal procedure, including the
Connection ofthe torque converter tothe drive plate.
1.2. Engine—Dismantling
Before commencing dismantling of th
exterior surfaces should be cleaned,
possible, to remove dirt or grease. Plug tt
‘openings with clean cloth first prevent any foreign
‘matter entering the cavities and openings. Detailed
information on engine dismanting and assemblyis
given in the sections dealing with servicing and
‘overhaul (sections commencingat 14.)and these
should be followed for each ofthe sub-assemblies
Cr units tobe dealtwith.
10 4 RS
cm
Follow the general dismantiing instructions given
below:
© Dismantling must be carried out in an orderly
fashion to ensure that parts, such as valves,
pistons, bearing caps, shells, tppets and soon, are
replaced in the same positions as they occupied
riginally. Mark them clearly, but take care not to
scratch or stamp on any rotating or bearing
surfaces. A good way to keep the valvesin orderis
bby piercing them through an upside-down cardbox,
as shownin Fig. 1.8 and writing the number against
each valve. Segregate together the tappets, the
‘springs and retainers with collets for each valve, if
possible in small plastic bags for each individual
valve.
© ‘If.a proper engine dismantling stand is not
available, it will be useful to make up wooden
Support blocks to allow access to both the top and
bottom faces of the engine. Thecylinderhead, once
removed from the block, should be supported bya
‘metal strap, screwed to the manifold face and
‘secured by two nutsonto the manifoldstuds,
© The normal order of removal of parts for a
‘complete engine strip-downis given below but this
may, of course, be modified it only partial
dismantlingis required.
© Remove all engine auxiliary parts, ¢. ignition
distributor inlet manifold, exhaust manifold, partsof
the fuel injection system, as applicable,
© Unscrew the timing belt guards and remove
the timing belt as described under the relevant
heading further on inthe engine section. Remove
the timing belt tensioner.
© Remove the crankshaft pulley together with
the crankshatt timing wheel from the crankshaft
end.
© Remove the cylinder head cover and discard
the gasket. Remove the cylinderhead together with
the gasket. Slacken the cylinder head bolts in
reversecrderto the one shown inFig. 19 andiittof
Remove the cylinder head gasket. Note that a
special polygon-socket head wrench is required
to remove the cylinder head bolts. Your VW
Dealer may have these in stock and no attempt
should be made to remove the bolts with make-shift
tools.
© Remove the water pump and the oilfiter. The
oil filter can also be unscrewed together with the
filter bracket, if this is prefered. To remove the filter,
Use a strap-type tool. Otherwise pierce a screw- driver through the side of the fiter and use the
handle as lever to unscrew the fier. The filter
should be replaced during assembly.
© Tum over the engine and remove the oil
‘sump. Check that the engine oll has been drai-
ned previously. Unscrew the oil pump from the
crankcase and withdraw from the engine.
© Check if there are any markings on the big
‘end bearing caps and if this is not the case, mark
the cylinder number with paint on each of the big
‘end bearing caps, starting with number one at the
front end of the engine. Fig. 1.10 shows the mar-
king of the connecting rod and bearing cap with
‘centre punch. Turn over the engine so that two
ofthe connecting rod big end bearings are at the
bottom dead centre position and unscrew the be-
aring caps. Remove the caps and the bearing
shells and keep them together, marked with their
cylinder number. Push the connecting rod and the
piston through the top of the cylinder bore, using
a hammer handle. Turn the crankshaft until the
other two connecting rod bearings are at the bot-
tom dead centre and remove in the same man-
ner. Note that stretch bolts are fitted to the
‘connecting rods which must not be re-used.
© Straight away after removal, refit the big end
bearing caps and the bearing shells to the con-
necting rods. Make sure that the bearing shells,
inside the connecting rods have also been
removed.
1 Four-cylinder Petrol Engine
© Remove the crankshaft. The bearing caps
‘are marked with numbers from 1 to 5 (No. 1 is
at the crankshatt pulley end). Remove the half
thrust washers from the centre crankshaft main
bearing.
© Unscrew and remove the intermediate shaft
timing gearwheel and then remove the mounting
flange. Carefully pry off the flange and withdraw
the shaft from the cylinder block.
NOTE: The oil seal for the intermediate shaft
may be marked with an arrow which must point *
in the rotating direction of the engine when the
oll seal is refitted. Fig. 1.11 shows an exploded
view of the crankcase and should be referred to
during dismantling and the following assembly.
Fig 1.11.
Exploded view of the
‘crankcase and erankshat
1 Man brn cap bot
2 Man bering cap
3 Toust wasn
etn ap
4 Upper beg shel
5 cranksran
6 Lover bexing sot
7 Tht nanan Bock
8 Bot, 10kgm
9 ltemedite shat
10 Ot el
11 Bot, 25 tg
12 lead sha Sango
19 Ol sa aays pace
14 Bot, 20 kgm
15 Front ol tl ange
16 Gast
1 Lower baring she
18 Usps baring shat
15 1 Four-cylinder Petrol Engine
1.3. Engine—Assembly
Refer to the sections commencing at 14, for details
of the assembly procedures for individual parts and
units. Follow the general instructions below at all
times. In general proceed in reverse orderto the dis-
mantling procedure, but note the points given
below:
© Take care that parts are only assembled in a
clean condition.
© Keep tools, benches and hands free from dirt
and swarf. Use only lint-ree rags to wipe over the
parts.
© Applyafilmot clean engine ollto all parts that
1.4.
1.4.0. CYLINDERHEADAND VALVES
1.4.00. Technical Data
Valves
Valve Head Diameters:
Inletvalves:
Exhaustvaives: .
Valve Length:
Inletvalves:
Exhaust valve
Valve Stem Diameters:
Inletvalves: ..
Exhaust valves:
Valveseatangle: ....
Valve edge thickness:
Valve Se:
Valve Seat Diameters:
Inletvalves: ... .
Exhaust valves:
Valve Seat Widths:
Inletvalves:
Exhaust valves:
Valve seat angle:
Upper correction angle:
Valve Guides
Installation temperature:
Innerdiameter: ....... +. f
Running clearance of valve stems:
slide or rotate. Do this BEFORE the parts are as-
sembled so that the lubricant is actually on the
bearing surfaces. Itwill NOT do to apply the oiltoa,
completedassembly.
© Make sure thatall partshave been properly in-
‘spected for wear and damage betore fitting. Renew
any parts that are not up tostandard.
© Obtain all spares and replacement parts from
an authorised dealer or distributor, quoting the vehi-
cle serial number and the engine number. The
manufacturers adopt a policy of continuous up-
dating and improvement and only their official
representatives are in a position to advise you of the
latest component improvements and their applica-
tion to yourparticular engine.
40.00 mm (1.575in.)
33,00 mm (1.299in.)
-1.00mm (3615in.)
‘90.80 mm (3.607 in.)
7.97 mm(0314in.)
795mm (0313in.)
oe 45°
- .05mm(0.02in.) min,
-39.20 mm (1.543in,
32.40mm(1.276in.)
20mm(a08in)
2.4mm (0.094in.)
soee eee A
ee ++ 80°
35 .« -Oylinderhead cold
8013-8035 mm (03154-03163in.)
. Seeunder "Valves" intext 1.4.0.1. Introduction
The cylinder head can be removed with the en-
gine in position in the engine compartment. Due
tothe design of the valve gear, tappets and cam-
shaft there are a number of special points
ing which the reader is advised to study before
‘attempting any work on the cylinder head. The
following should be noted before any work is car-
ried out on the cylinder head:
‘The overhead camshaft is supported in five bear-
ings, the rear one providing axial location. There
is no No. 4 camshatt bearing. In its place an oil
return flow checkin the oil gallery for the hydraulic,
tappets is fitted.
There is a special procedure for removing the
camshaft for access to the valve springs and tap-
pets and this must be followed to avoid distortion
of the camshaft from the pressure of the valve
springs. A number of special tools, or suitably
made-up alternatives, will be required for servic
ing and the reader is advised not to undertake
‘such work unless the proper equipment is avail
able. The camshaft for a particular engine has a
certain marking and only a camshaft with the
same marking must be used if the part is
replaced.
‘The valve retainers, springs and stem seals are
rather inaccessible, being in pockets in the head.
We shall be describing the removal and installa~
tion procedures, using the special tools and
procedures recommended and will mention those
that are essential for the work. When removing
the valves, itis useful to note the order in which
the parts will be taken out once the camshaft is
removed: Valve cotter halves, top spring retain-
er, inner and outer vaive springs, valve seal and
bottom spring retainer.
1.4.0.2. Servicing
Remove all auxiliary parts from the cylinder head,
depending on the version. Make up a bracket
which can be attached to the studs for the exhaust
manifold and clamp the bracket into a vice. The